exco54 doc 04.02 t hermochem r ecovery i nternational...chem r ecovery i nternational exco54 doc...

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Recovery Int’lT hermoChem

An Introduction to

T Chem R ecovery I nternational hermo

www.tri-inc.net

ExCo54 Doc 04.02


Pulp Mill – Current Technology

Steam

Black Liquor

Lime Mud (CaCO3)

White Liquor(NaOH/Na2S)

Re-burnedLime (CaO)

LIQUOR MAKING

LIME KILN

RECOVERYBOILER

PULP MILL

Fuel

Green Liquor(Na2CO3/Na2S)

Liquor Loop

Wood

Pulp

Pulp

BleachPlant

Paper Machine

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World wide commercialization of proprietary technology for advanced chemical and energy recovery systemsin the pulp and paper industry

• 21 years in development• Over $30 million in R&D investment, grants and cost-sharing

agreements with the U.S. Department of Energy, California Energy Commission, the Pulp and Paper Industry, U.S. Trade and Development Agency, National Labs

• Two commercial facilities in startup

T Chem R ecovery I nternational hermo


It is NOT Combustion:

C + O2 = CO2 + Heat

H + O2 = H2O + Heat

What is …Biomass Steam Reforming?

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Ø Medium temperature, atmospheric pressure exposure to steam in the absence of air or oxygen

Ø Organics are converted to hydrogen and carbon monoxide

H2O + C + Heat = H2 + CO

Ø Carbon Monoxide reacts with steam to formmore hydrogen and carbon dioxide

CO + H2O = H2 + CO2

What is …Biomass Steam Reforming?


• Proprietary Technology

– Unique application of steam reforming

– PulseEnhancedTM

combustion

• Converts Organic Feedstocks to a H2 Rich Syngas

• Power Generation

• Production of Bio-based Fuels and Chemicals

TRI’s Technology

Fluidizing Steam

Bed Solids

H2 rich Syngas

Biomass orBlack Liquor

CleanFlueGasFuel

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Reformer Bed Solids (Na2CO3)


• Indirectly Heated• Low Temperature• No Air/No Oxygen• Dry Inorganic Recovery• High Residence Time• Uniformity

PulseEnhancedTM Steam Reformer

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• H2 - Rich Product Gas • Low Emissions• Additional Export Steam• Elimination of Smelt/Eutectics• Purging of NPEs• Low Capital Cost• Stable Operation• Versatile Processing...

PulseEnhancedTM Steam Reforming


Spent Liquors• Soda• Kraft• Sulfite• Semi-Chemical• Cross Recovery• Silica-Laden Liquors

Biomass• Sludge• Hogged Bark• Sawdust• Wood Chips• Pith

Versatile Processing…. P&P

Pulsed Jet Heater

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H2:CO Ratio can be varied to meet Process Requirements

• BL 8:1 to 2:1– High H2 production for fuel cells– High energy fuel for combustion

• Biomass 2:1 to 0.5:1• Feed for Fischer-Tropsch processes• Feed for digester processes• Ethanol production

Versatile Syngas Production

Hydrogen 65%

C2+3%

Carbon Dioxide

19%

Carbon Monoxide

8% Methane5%

HHV 330 Btu/dscf


Pulsed Jet Heater Module

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1. Ignition 2. Expansion

3. Purge and Recharge 4. Compression

Pulsed Heater Operator Principle


Pulsed Combustor - ComponentsCombustion

Chamber ResonanceTubes

ExhaustPlenum

AerovalvePlate

Mounts Here

NORAMPAC INC., Presentation to IEA ANNEX XV Semi-Annual Meeting, Atlanta, FEBRUARY 2004

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• Fuels Flexibility• Enhanced Heat Transfer• Uniform Heat Flux• High Combustion Efficiency• Low NOX Emissions• No Moving Parts• Self Aspiration• Pressure Boost

Pulsed Jet Combustion - Advantages


ReformerVesselDesign

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LiquorInjection

PulsedHeaters

Bed Solids

HRSG #1HP

Superheater

Filter

Export Steam

GasCleanup

H2SAbsorber

Steam Turbines

Mix Tank

Gas Turbine

Flue Gas

Steam

LPSuperheater

Raw Gas

Cyclone

Product Gas Compressor

Air

HRSG #2

GreenLiquor

Na2CO3 Solution Dregs

Stack

ProductGas

Superheated Steam

• Proprietary Equipment & Systems

– Steam Reformer– Pulse Heaters– Steam Injection– Liquor Injection

• Ancillary systems– Cyclones– Superheaters– Bed Solids Material

Handling & Dissolving

– Green Liquor Filtering

• Process Design• Technology License

TRI’s Products


Norampac• Norampac, Inc., a joint venture between Domtar and

Cascade, is Canada’s largest containerboard manufacturer

• Norampac currently has no recovery system; previously used black liquor as a binders on forestry roads

• StoneChem scope includes:– Steam Reformer– Pulse Combustors and Fuel Train– Detailed engineering and startup support– Materials handling equipment– Instrumentation

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Norampac

Steam

Sodium Carbonate

FilterCake

BedSolids

Mix Tank

Wash/Filter

Sodium Carbonate Solution

Stack

Boiler

Raw Gas

ProductGas

Flue Gas

Steam

Steam

SuperHeater

Spent Liquor

NaturalGas

Storage Bin

Natural Gas


Steam Reformer Island

Norampac

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NorampacBenefits:

Chemical Recovery: 99% Sodium recovery. 96.6% carbon conversionEnvironmental: Very low emissionsEnergy: Net energy recovery at design capacity 26MM Btu/hrScale: Capacity for full recovery of current and future mill liquor solids production


Steam Reformer Building

Norampac

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Pulse Heater Installation


Pulsed Heater In Operation

Norampac

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Pulse Heater Tubes in Reformer

Norampac


Steam Distributor and Injectors

Norampac

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Norampac Startup Update• Construction was completed and commissioning and

Start-up begun in Sept. 03

• The reformer operated at essentially 100% availability from October through December of 03• System reliably recovered chemicals to meet pulp mill needs

• Ancillary systems worked per design

• Product gas fired in the boiler per design

• Mill personnel assumed all operational responsibility

• The process was shutdown in January 04 to install process modifications

• The plant was re-started in May 04 and significant progress made against syngas production and throughput targets


Georgia-Pacific

• Containerboard mill in Big Island, Virginia• Part of the “Agenda 2020” initiative and 50%

funded by the U.S. Department of Energy • Steam Reformers replace existing smelters and

provide total chemical recovery for the mill• Meets MACT environmental regulations• Co-funded by DOE• StoneChem scope :

– Process design package for reformer system– 8 Pulse Combustion Heaters

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Georgia-Pacific

Reduction in Emissions

53.7%

77.3%

3.4%0.5%1.9% 0.4%0.1%0.2%

7.9%11.5%

0%

20%

40%

60%

80%

100%

NOx SO2 CO VOC Particulate

% o

f Sm

elte

r E

mis

sio

ns

Recovery Boiler Gasifier

Benefits:– Environmental: 90% reduction in emissions.

– Chemical Recovery: Sodium recovery efficiency increase of 2%.– Pulp Yield and Quality: Potential pulp yield increase of up to 5%.– Energy: Use of non-renewable and fossil fuels will be reduced.

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Georgia-Pacific Startup Update• Construction was completed in 4th quarter of 03 and

commissioning was commenced in the 1st quarter of 04

• There were significant bed fluidization problems caused by incorrect steam distributor design.

• A cold flow model study was undertaken and a new distributor design was developed and installed.

• The system was then successfully started up and is currently in commissioning


TRI’s Technology Benefits

• Utilization of FP Industry’s Biomass Resources– Wide variety of Spent Liquors– Broad range of Biomass (Residuals to Sludge)– Host for other Biomass processing (agricultural waste to

RDF)

• Aging Recovery Assets & Technology– Improved Energy production efficiency– Elimination of smelt/water explosions– Improved environmental performance– Cost effective capacity debottlenecking – incremental

production– Enables advanced pulping technologies for increased

fiber yields

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Potential of TRI’s Technology

Chemical Recovery

Product Gas (H2, CO)

Steam

Carbon Sequestration Environmental FertilizerActivated Carbon

Clean Power Combined CycleFuel Cell

Offset Fossil FuelsKiln, Boiler, Driers, etc.

Ref

orm

er

Spent LiquorBio-derived FuelsEthanol, MethanolBio-diesel

Bio-derived ChemicalsAcetic acid, plastics,Ammonia

Additional Biomass

Wood product residuals,Hog fuel ,Sludge,Recycle rejects, Agricultural waste

Chemical Recovery

Product Gas (H2, CO)

Steam

Carbon Sequestration Environmental FertilizerActivated Carbon

Clean Power Combined CycleFuel Cell

Offset Fossil FuelsKiln, Boiler, Driers, etc.Offset Fossil FuelsKiln, Boiler, Driers, etc.

Ref

orm

er

Spent LiquorBio-derived FuelsEthanol, MethanolBio-diesel

Bio-derived FuelsEthanol, MethanolBio-diesel



Additional Biomass

Wood product residuals,Hog fuel ,Sludge,Recycle rejects, Agricultural waste

Bio-Refineryof the Future

• Maximizes value of forest resources

• Utilizes other biomass resources

• Manufactures paper and wood products

• Manufactures bio-chemicals and fuels

• Exports electricity

• Provides compelling ROI

• Improves the environment

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